U.S. patent application number 12/620896 was filed with the patent office on 2010-03-18 for single component flat panel cooling apparatus.
Invention is credited to Mark D. Fuchs.
Application Number | 20100064720 12/620896 |
Document ID | / |
Family ID | 42006016 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100064720 |
Kind Code |
A1 |
Fuchs; Mark D. |
March 18, 2010 |
Single Component Flat Panel Cooling Apparatus
Abstract
The present invention is a unitary cooling apparatus capable of
standard freezing time despite heavy insulation. One embodiment of
the apparatus includes a zipper component which extends along the
edges of a top surface and bottom surface allowing the top and
bottom to be pivoted outward or inward and the cooling apparatus
flattened along the seams which connect the sides. A plurality of
cube structures positioned along a plurality of channels allows
rapid cooling using a minimum of frozen fluid.
Inventors: |
Fuchs; Mark D.; (Mequon,
WI) |
Correspondence
Address: |
ABSOLUTE TECHNOLOGY LAW GROUP LLC
135 W. WELLS ST., SUITE 518
MILWAUKEE
WI
53203
US
|
Family ID: |
42006016 |
Appl. No.: |
12/620896 |
Filed: |
November 18, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11110179 |
Apr 20, 2005 |
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12620896 |
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Current U.S.
Class: |
62/457.7 ;
29/890.035; 62/457.9 |
Current CPC
Class: |
F25D 2331/805 20130101;
Y10T 29/49359 20150115; F25D 2331/801 20130101; F25C 1/22 20130101;
F25D 2303/08223 20130101; F25D 2323/061 20130101; F25D 3/08
20130101; F25D 2331/803 20130101 |
Class at
Publication: |
62/457.7 ;
62/457.9; 29/890.035 |
International
Class: |
F25D 3/08 20060101
F25D003/08; B21D 53/02 20060101 B21D053/02 |
Claims
1. A single component flat panel cooling apparatus designed to be
inserted directly into a freezer comprised of: four unitary
freezing panels joined at the sides to form a single rectangular
structure that may be collapsed to a substantially flat position
for storage within a freezer; a bottom surface which pivots
backward into a flush position over said rectangular structure in a
collapsed position; a top surface which pivots backward into a
flush position over said rectangular structure in a collapsed
position; and at least one weight resistant zipper.
2. The single component flat panel cooling apparatus of claim 1
wherein each of said four unitary freezing panels are comprised of:
a fabric layer; an insulation layer; an inner reflective layer; a
top layer and a backing layer containing a plurality of cubes with
a plurality of channels between said cubes filled with fluid; and a
polyethylene layer.
3. The single component flat panel cooling apparatus of claim 2
wherein said fabric layer is a nylon blend containing anti-freeze
material.
4. The single component flat panel cooling apparatus of claim 2
wherein said insulation layer is notched foam.
5. The single component flat panel cooling apparatus of claim 2
wherein said inner reflective layer is PE-LD metalized
polyethylene.
6. The single component flat panel cooling apparatus of claim 2
wherein said top layer and said backing layer are layers of a blend
of polyester and nylon.
7. The single component flat panel cooling apparatus of claim 1
wherein said cooling apparatus is has a height of one to three
inches in the collapsed position.
8. The single component flat panel cooling apparatus of claim 2
wherein said cubes are filled with a fluid other than water and
channels which allow for circulation of air between said cubes in a
freezer.
9. The single component flat panel cooling apparatus of claim 1
wherein said top surface and said bottom surface further include an
insulation layer.
10. The single component flat panel cooling apparatus of claim 1
wherein said top surface and said bottom surface further include an
inner reflective layer.
11. The single component flat panel cooling apparatus of claim 1
which further includes a panel insertion channel.
12. A method of manufacturing a single component flat panel cooling
apparatus designed to be directly inserted into a freezer comprised
of: assembling unitary freezing panels, said four unitary freezing
panels comprised of a fabric layer, an insulation layer, an inner
reflective layer, a multi-channeled fluid layer containing a
plurality of ice cubes separated by channels and a polyethylene
layer, attaching said polyethylene layer to said inner reflective
layer using stitching wherein said stitching runs along at least
one of said channels; attaching said four unitary freezing panels
together to form a rectangular structure having flexible seams
between said four unitary freezing panels; adding a zipper along
the top edge of said rectangular structure and a zipper along the
bottom edge of said rectangular structure, wherein said zippers are
double-stitched to said rectangular structure to further secure
said fabric layer, said insulation layer, said inner reflective
layer, said multi-channel fluid layer and said polyethylene layer
of said four unitary freezing panels together; and attaching a top
surface with a zipper along one of said top edges of said
rectangular structure and a bottom surface with a zipper to one of
said bottom edges of said rectangular structure using a panel of
fabric which permanently secures said top surface and said bottom
surface to said rectangular structure and allows said top surface
and said bottom surface to pivot backward and flat.
13. The method of manufacturing a single component flat panel
cooling apparatus of claim 12 which further includes creating
channels between said plurality of ice cubes to allow for
circulation of air between said plurality of cubes when stored in a
freezer.
14. The method of manufacturing a single component flat panel
cooling apparatus of claim 12 which further includes creating seams
so that said rectangular structure may be flattened and said top
surface and said bottom surface pivoted.
15. A single component flat panel cooling apparatus designed to be
inserted directly into a freezer comprised of: four unitary
freezing panels joined at the sides to form a single rectangular
structure that may be collapsed to a substantially flat position
for storage within a freezer; wherein said rectangular structure
folds to less than three inches; a bottom surface which pivots
backward into a flush position over said rectangular structure in a
collapsed position; a top surface which pivots backward into a
flush position over said rectangular structure in a collapsed
position; and at least one weight resistant zipper.
16. The single component flat panel cooling apparatus of claim 15
wherein each of said four unitary freezing panels are comprised of:
a fabric layer; an insulation layer; an inner reflective layer; a
top layer and a backing layer containing a plurality of cubes with
a plurality of channels between said cubes filled with fluid having
a standard freezing time; and a polyethylene layer.
17. The single component flat panel cooling apparatus of claim 15
wherein said top surface and said bottom surface further include an
insulation layer.
18. The single component flat panel cooling apparatus of claim 15
wherein said top surface and said bottom surface further include an
inner reflective layer.
19. The single component flat panel cooling apparatus of claim 15
herein said fabric layer is a nylon blend containing anti-freeze
material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application that
claims priority to U.S. application Ser. No. 11/110,179 filed on
Apr. 20, 2005.
FIELD OF INVENTION
[0002] The present invention relates to the field coolers and more
specifically to a cooler with integrally constructed freezing and
insulating components which can be flattened to less than three
inches to be stored in a freezer in a flattened position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 illustrates an exemplary embodiment of a plurality of
single component flat cooling apparatuses in a flattened position
and stacked in a residential-size freezer:
[0004] FIG. 2 illustrates an exemplary embodiment of a single
component flat cooling apparatus in the non-flattened position.
[0005] FIG. 3 illustrates an exemplary embodiment of a single
component flat panel cooling apparatus which has a pivotal top and
pivotal bottom capable of being pivoted to a substantially flush
position against a unitary freezing panel in a flattened
position.
[0006] FIG. 4 illustrates the range of motion of pivotal top and
pivotal bottom components capable of operating as the top and
bottom of a structure and secured with a zipper component or moved
to flush position against a unitary freezing panel in a flattened
position.
[0007] FIG. 5 illustrates a side perspective view of an exemplary
embodiment of a single component flat cooling apparatus in a
flattened position for space-efficient storage within a
freezer.
[0008] FIG. 6 illustrates a cross-sectional view of a integrally
constructed insulating and freezing layers of single component flat
cooling apparatus.
GLOSSARY
[0009] As used herein, the term "fluid" refers to a substance used
for cooling (creating ice or other frozen component). Examples of
fluid include water, water with additives, a gel solution (e.g.,
hydroxyethyl cellulose (Cellusize.TM.), vinyl-coated silica gel) or
another substance or solution capable of providing a chilling
effect on surrounding materials by absorbing heat.
[0010] As used herein, the term "unitary freezing panel" means a
component of a cooling apparatus made up of a plurality of layers,
including, but not limited to, freezing, reflective and/or
insulating layers. For example a flat panel may be comprised of
multiple freezing and insulation layers, including but not limited
to a fabric layer, an insulation layer, an inner reflective layer,
a multi-channeled fluid layer and a polyethylene layer.
[0011] As used herein, the term "multi-channeled" means having
openings, lanes, spacing, etc. (horizontal or vertical) between
structural components (e.g., freezing cubes, bubbles and/or
pockets). Channels may be created by sewing, heat sealing,
stamping, molding, machining and combinations thereof.
[0012] As used herein, the term "standard freezing time" refers to
a freezing process which occurs during a measurable time frame,
e.g., the normal time frame for freezing of water.
[0013] As used herein, the term "panel insertion channel" is a
portion of a cooler which allows a component of a machine used for
embellishment to be more easily used. For example, a panel
insertion channel may be an extra panel of fabric attached to one
or more unitary freezing panels of the cooling apparatus which
allows for insertion of a component of an embroidery or silk
screening machine.
[0014] As used herein, the term "anti-freeze fiber additive" means
an additive added to fibers of a layer, such as a fabric layer,
insulation layer, reflective layer, fluid layer or any other layer,
that makes it resistant to cracking when frozen. For example, an
anti-freeze material may be added to fibers during the
manufacturing process.
[0015] As used herein, the term "weight resistant zipper" means a
fastener that temporarily joins two edges of fabric and is capable
of withstanding a substantial amount of weight. For example, a
weight resistant zipper may be capable of joining two edges of
fabric under 200 pounds of weight.
[0016] As used herein, the term "notched seam" means a component
which creates a seam by notching foam or other material.
[0017] As used herein, the term "bottom" or "bottom surface" means
the underside of a cooling apparatus.
[0018] As used herein, the term "top" or "top surface" means the
uppermost side of a cooling apparatus.
BACKGROUND
[0019] There are many types of portable coolers known in the art,
and in particular many coolers which collapse to facilitate
storage. Most coolers have some sort of insulated sides to prevent
rapid temperature change. Others utilize removable ice-pack
components stored in and inserted within packets or into
compartments of a cooler.
[0020] The average size of the freezer compartment in a top/bottom
refrigerator/freezer is 4.1 cubic feet, which is not large enough
to accommodate a cooler. These freezer compartments generally have
one or more shelves which limit the size of the items which the
freezer can accommodate. Side by side refrigerators/freezers
generally have a larger size freezer, e.g., 9.9 cubic feet;
however, they have multiple shelves which maximize the number of
items that can be stored while limiting the size of the items.
Commercial coolers are also available; however, they are typically
used to store other things.
[0021] Coolers known in the art are not specifically designed to be
placed in a freezer without disassembly of components. Coolers with
hard shells of molded plastic will accumulate frost if left in a
freezer for an extended period and when removed from the freezer
moisture will form on the outside of the cooler. Coolers having
less-rigid vinyl sides are also susceptible to the formation of
moisture when removed from a freezer and also to cracking when
frozen.
[0022] Ice packs can also offer the ability to store freezing
components in the limited space available in a residential-size
freezer; however, they offer limited cooling capacity and must
generally be inserted separately into coolers.
[0023] Because of the space constraints in freezers and the
material from which coolers are constructed, ice packs are inserted
into coolers requiring coolers to have several components which
need to be removed when the cooler is not in use and re-inserted
when a cooler is in use. Ice packs take up a lot of otherwise
usable space within the interior of the cooler if they are not
designed to compactly fit within the cooler.
[0024] For example, U.S. Pat. No. 4,311,022 (Hall '022) discloses
an example of an ice pack. The ice pack constructed of a plurality
of separate compartments which are connected together through a
webbing assembly allowing the ice pack to be folded into a variety
of different shapes. The ice pack must be stored in the freezer and
separately inserted into the cooler and again removed after each
use. The ice packs can be stored in the freezer, but the cooler
cannot be.
[0025] There have been numerous attempts known in the art to create
a cooler structure which can be stored in a freezer. One example is
disclosed in U.S. Pat. No. 5,582,028 (Rilling '028). Rilling '028
teaches a cooling that is designed to be flexible and adjustable in
a way that allows the user to fit the pack closely around a variety
of different containers or objects that he or she is trying to keep
cold. This cooling pack is also designed to be foldably compact,
allowing it to be laid out flat or folded up to conserve storage
space when the pack is not in use or being frozen. Although, the
cooling device disclosed by Rilling '028 is foldable into a
somewhat collapsible position, this attempt is not satisfactory
because the cooling pack still requires the removal of one or more
components before it is capable of being efficiently stored within
a freezer.
[0026] Another example of a portable cooler with permanent frozen
inserts is disclosed in U.S. Pat. No. 5,490,396 (Morris '396).
Morris '396 teaches a collapsible cooler bag made of a flexible
material. A refrigerant gel is enclosed as a layer in between the
inner and outer surfaces of the cooler bag. The gel is flexible and
the cooler itself are made of flexible material; therefore, the
entire container may be compressed or folded in a relatively flat
position in order to be easily placed in a freezer so that the gel
can be frozen. This attempt is not satisfactory due to the amount
of time required to freeze the refrigerant gel. The refrigerant gel
is contained within a single compartment inserted between layers
and not divided into smaller compartments, which freeze faster.
[0027] Another example of a portable cooler with permanent frozen
inserts is disclosed in U.S. Pat. No. 7,302,810 (McCrory '810).
McCrory '810 teaches a soft walled cooler composed of two quilted
layers. Between these layers are a plurality of permanently
attached gel pockets that can be frozen to aid in insulating and
cooling the contents stored within. The cooler is foldable in the
areas of the walls that fall in between the gel pockets. This
design is not desirable because the insulating layers slow down the
freezing of the cubes. In addition, the cooler cannot be neatly
folded into a flat configuration.
[0028] It is desirable to have a cooling apparatus which includes
freezing components that are not inhibited from rapid freezing and
are not inhibited by the use of insulating layers.
[0029] It is further desirable to have an integrally constructed
cooling apparatus which can be flattened and stored in a
residential-size freezer, and is capable of rapid freezing when in
a collapsed position.
[0030] It is further desirable to have an integrally constructed
cooling apparatus that is less than two to three inches thick when
folded to conserve freezer space.
[0031] It is further desirable to have an integrally constructed
cooling apparatus which is specially designed to be inserted
directly into a freezer.
SUMMARY OF THE INVENTION
[0032] The present invention is a unitary cooling apparatus capable
of being stored in a freezer and allows the cooling components to
freeze in a normal freezing time despite the integral construction
of both freezing and insulating components. Channels create
circulation of frozen air and this effect is enhanced by reflective
elements.
[0033] One embodiment of the apparatus includes a zipper component
which extends along the edges of a top surface and bottom surface
allowing the top and bottom to be pivoted outward or inward and the
cooling apparatus flattened along the seams which connect the four
unitary freezing panels. A plurality of cube structures positioned
along a plurality of channels allows rapid cooling using a minimum
of frozen fluid.
[0034] The unitary freezing panels are comprised of a plurality of
layers. The outermost layer is a fabric layer. Next to the fabric
layer is an insulation layer followed by an inner reflective layer.
A multi-channeled fluid layer containing spaced apart cubes filled
with fluid is sandwiched between the inner reflective layer and a
polyethylene layer. The polyethylene layer is sewn to the other
layers along channels between sets of the cubes.
[0035] When the cooling apparatus is in a flattened position, i.e.,
top and bottom pivoted flat against cooling apparatus folded along
the seams, multiple flattened coolers can be stored in a small
space, such as a standard-size freezer.
DETAILED DESCRIPTION OF INVENTION
[0036] For the purpose of promoting an understanding of the present
invention, references are made in the text to exemplary embodiments
of a single component flat cooling apparatus with a multi-channeled
fluid layer, only some of which are described herein. It should be
understood that no limitations on the scope of the invention are
intended by describing these exemplary embodiments. One of ordinary
skill in the art will readily appreciate that alternate but
functionally equivalent components, structures and materials may be
used. The inclusion of additional elements may be deemed readily
apparent and obvious to one of ordinary skill in the art. Specific
elements disclosed herein are not to be interpreted as limiting,
but rather as a basis for the claims and as a representative basis
for teaching one of ordinary skill in the art to employ the present
invention.
[0037] It should be understood that the drawings are not
necessarily to scale; instead, emphasis has been placed upon
illustrating the principles of the invention. In addition, in the
embodiments depicted herein, like reference numerals in the various
drawings refer to identical or near identical structural
elements.
[0038] Moreover, the terms "substantially" or "approximately" as
used herein may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related.
[0039] FIG. 1 illustrates an exemplary embodiment of unitary
cooling apparatuses 100a-100d stored in a flattened position in
freezer 77. As shown in FIG. 1, unitary cooling apparatuses
100a-100d are extremely space efficient.
[0040] FIG. 2 illustrates an exemplary embodiment of unitary
cooling apparatus 100 with multi-channeled fluid layer 40 in an
expanded position. Cooling apparatus 100 is comprised of four
unitary freezing panels 10a-10d, top surface 20 and bottom surface
30. Each unitary freezing panel 10a-10d has multi-channeled fluid
layer 40 fixedly attached. Multi-channeled fluid layer 40 is
comprised of a plurality of spaced-apart cubes 45 filled with
fluid. In the embodiment shown, cubes 45 are rectangular and are
filled with purified water. In other embodiments, cubes 45 are of
another shape, such as square, circular, or triangular and are
filled with a fluid other than water, such as a gel solution.
[0041] Cooling apparatus 100 further includes zippers 50a, 50b.
Zipper 50a runs along all four sides of top surface 20 and zipper
50b runs along four sides of bottom surface 30. Top surface 20 and
bottom surface 30 are attached to cooling apparatus 100 using
fabric piece 18a, 18b (visible in FIG. 3) sewn over the zipper on
one edge (i.e., top edge of unitary freezing panel 10c and bottom
edge of unitary freezing panel 10c). Fabric piece 18a, 18b prevents
top surface 20 and bottom surface 30 from being completely unzipped
from cooling apparatus 100 and also allow top surface 20 and bottom
surface 30 to be pivoted backward and flat.
[0042] When zippers 50a, 50b are open, top surface 20 and bottom
surface 30 can be pivoted outward or inward and unitary freezing
panels 10a-10d can be folded along seams 15b, 15d (seams 15a, 15c
will be flat) or along seams 15a, 15c (seams 15b, 15d will be flat)
into a flat configuration. When cooling apparatus 100 is in the
collapsed flat configuration, it will easily fit in a standard
freezer for freezing the fluid in cubes 45 or into a small space
for storage.
[0043] In the embodiment shown, cooling apparatus 100 further
includes strap 60. Strap 60 may be fixedly attached to cooling
apparatus 100 (e.g., sewn) or removably attached to cooling
apparatus 100 (e.g., hook and loop fasteners or snaps). Cooling
apparatus 100 may further include an optional panel insertion
channel. For example, cooling apparatus 100 may include an extra
panel of fabric on unitary freezing panel 10a which allows for easy
embroidering or silk screening (plate slides between extra panel
and fabric layer).
[0044] FIG. 3 illustrates an exemplary embodiment of unitary
cooling apparatus 100 with multi-channeled fluid layer 40 in a
collapsed position with top surface 20 and bottom surface 30
pivoted upward.
[0045] FIG. 4 illustrates an exemplary embodiment of unitary
cooling apparatus 100 with multi-channeled fluid layer 40 in a
collapsed position with top surface 20 and bottom surface 30
pivoted outward and cooling apparatus 100 folded along seams 15b,
15d so that seams 15a, 15c are flat.
[0046] FIG. 5 illustrates a side perspective view of an exemplary
embodiment of unitary cooling apparatus 100 with multi-channeled
fluid layer 40 in a collapsed position with top surface 20 (not
visible) and bottom surface 30 pivoted backward. In the embodiment
shown, zippers 50a, 50b (not visible) are open, top surface 20 and
bottom surface 30 are pivoted backward against unitary freezing
panel 10c and cooling apparatus 100 is folded along seams 15b, 15d
(seams 15a, 15c are flat) into a collapsed position for placing in
a freezer or for economical storage.
[0047] Visible are polyethylene layer 48 and cubes 45 of
multi-channeled fluid layer 40. Also visible are channels 44a-44f
between cubes 45 and seams 58a-58d. When cooling apparatus 100 is
in an upright position (as in FIG. 2), channels 44a-44f run
vertically between cubes 45. There are also channels which run
horizontally between cubes 45 (not visible); therefore each cube 45
is spaced apart from the cubes surrounding it.
[0048] Multi-channeled fluid layer 40 manufactured in sheets of
evenly spaced apart cubes 45. The sheets are cut to the desired
size/number of cubes by cutting between the cubes in the channels.
For example, in an exemplary embodiment of cooling apparatus 100,
unitary freezing panels 10a, 10c may contain four columns of five
cubes for a total of twenty cubes and unitary freezing panels 10b,
10d may contain two columns of five cubes for a total of ten cubes.
Polyethylene layer 48 is placed over multi-channeled fluid layer 40
and sewn to inner reflective layer 40 (not labeled) along lanes
58a, 58b and at seams 15a-15d.
[0049] Opening zippers 50a, 50b allows air to go flow through
cooling apparatus 100 allowing for standard freezing time of cubes
15. The channels between cubes 45 also aid in the freezing of cubes
45 by exposing a greater surface area of cubes 45 to the cold air.
In addition to being important for standard freezing time, the
channels allow for flexibility in unitary freezing panels 10a-10d
even when cubes 45 are frozen.
[0050] FIG. 6 illustrates a cross-sectional view of unitary
freezing panel 10a of an exemplary embodiment of unitary cooling
apparatus 100 with multi-channeled fluid layer 40. In the
embodiment shown, each unitary freezing panel 10 of cooling
apparatus 100 is comprised of a fabric layer 56, insulation layer
54, inner reflective layer 52, multi-channeled fluid layer 40 and
polyethylene layer 48. In other embodiments, unitary freezing
panels 10a-10d may be comprised of a larger or smaller number of
layers.
[0051] In the embodiment shown, fabric layer 56 is comprised of a
nylon blend and is water resistant. Additives ("anti-freeze
material") are added to the fibers of the fabric during the
manufacturing process which prevents the fabric from cracking when
frozen. In other embodiments, fabric layer 56 may be comprised of
another material or combination of materials that does not crack
during freezing and remains flexible when frozen.
[0052] In the embodiment shown, insulation layer 54 is comprised of
notched foam. In other embodiments, insulation layer 54 is
comprised of another type of foam or other insulating material
known in the art (e.g., fiberglass, coat).
[0053] In the embodiment shown, inner reflective layer 52 is
comprised of PE-LD metalized polyethylene. Inner reflective layer
52 reflects cold air back into the interior of the cooler and
slowing the passing of cold air through the side of the cooler.
Inner reflective layer 52 reduces conductivity and slows molecules
helping maintain a lower temperature inside cooling apparatus 100.
In other embodiments, inner reflective layer is made up of another
type of reflective material, such as aluminum foil.
[0054] In addition to inner reflective layer 52, top surface 20 and
bottom surface 30 may also include a reflective layer (not
shown).
[0055] Multi-channeled fluid layer 40 is comprised of backing layer
46 and top layer 42 which is formed into cubes 45. In the
embodiment shown, backing layer 46 and top layer 42 are comprised
of layers of LDPF polyester/nylon that is flexible and does not
crack when frozen, is puncture resistant and reduces air flow
(i.e., has limited porosity). In other embodiments, top layer 42
and backing layer 46 are comprised of another material with similar
properties. This composition of layers allows for a normal freezing
time despite the integral construction of both freezing and
insulating components.
[0056] Multi-channeled fluid layer 40 is secured to inner
reflective layer 52, insulation layer 54 and fabric layer 56 by
polyethylene layer 48. Polyethylene layer 48 is comprised of food
grade, low density polyethylene which is placed over
multi-channeled fluid layer 40 and is sewn to inner reflective
layer 52 at lanes 58a-58c.
* * * * *